Robot-Assisted and Fully Automated for the Implementation of Industrie 4.0

Grinding, Deburring, and Mechanically Processing Aluminum Structural Components in a Single Process

Automobiles are becoming increasingly lighter, due to steel being replaced more
and more by lighter materials, such as aluminum, during the manufacturing
process. SHL AG has seized upon this development and created a system that
grinds, deburrs, and then mechanically processes aluminum structural components
– in a single, fully automated, robot-assisted process. SHL designed the
manufacturing line as the general contractor for a medium-sized automotive
supplier that is very enthusiastic about the line’s performance.

The growing use of light materials
also requires processing technology.
The processing of aluminum
structural components with complex
geometries is challenging; the
requirements for surface quality
are high. Robot-based solutions
that carry out several steps in
a fully automated manner are
advantageous here. They make
processes leaner, saving the user
time and money. When designing
the manufacturing line, SHL used
its over 30 years of experience in
the processing of aluminum, thus
providing an important element for
connected production in the context
of Industrie 4.0. With the help
of industrial robots, structural components,
such as suspension strut
supports, are ground, deburred,
and measured in a fully automated
manner. Then comes mechanical
processing with drilling and milling.
Afterwards, the components are
straightened, inspected, and
riveted. „This is done in a single
process. As a general contractor,
we offer our clients service from
a single source with dedicated
contact persons,“ explains SHL
project manager Daniel Welte.
Several production runs have
already taken place at company
headquarters in Böttingen, to the
full satisfaction of the supplier.

The belt grinding units developed
by SHL offer users long-term ideal
grinding results combined with
cost-effective consumption costs.
An audit report from TÜV highlights
the suitability of SHL solutions
specifically for aluminum grinding.
In the new, 3,000-square-meter
hall for application technology,
SHL can easily design and install
entire large production lines. The
company currently supplies all
renowned foundries with systems
and grinding know-how from Böttingen.
The processing procedure
on the manufacturing line begins
with the aluminum structural
components on a heat treatment
frame. An employee enters a data
matrix code; the MES system then
approves the „grinding“ process.
Afterwards, the component is
placed on the loading table. Robot
number one grabs the components
and brings one after the other to
two SHL FKS 250/450 free contact
wheel grinding machines. These
have retrofitting spindles, contact
wheels, and grinding attachments.
The robot then activates the SHL
P 550 deburring unit and completes
interior processing. In a direct „Shake Hand“ procedure,
it hands over the component
to robot number two.
Then comes exterior processing,
using the same
machine configuration
as in the first step. The
component is then placed
in the blow-off port, where
air pressure removes
dust particles.

After that,
the component is handed
over to the handling robot.
This robot has a data
matrix code scanner that
decides the next step. If
problems arise during the
grinding process, such
as a drop in air pressure
or belt break, robot
number three unloads the
component on the Non-
Compliant belt. “If the
system does not detect
any problems, the components
are placed in the
straightening system and
positioned accordingly,“
explains Daniel Welte. If
there are discrepancies,
components will also be
unloaded on a separate
belt, reworked, and reloaded
via the Sequence
Part Control. Only after
that does the robot activate
the CNC machine for
the milling process.

Since
the component is subjected
to powerful forces
during milling, a distortion
check is carried out. If this
verification is OK, robot
number three applies two/
four blind rivet bolts, the
correct position of which
is verified through a force/
displacement measurement.
If there are deviations
from the prescribed
norm, the component has
to be reworked. If this is
not the case, the robot
removes the component
and places it on the belt;
the process is complete.
The system is available
for the next component.
With this manufacturing
line, SHL developed an
automated solution with
an overarching SPS
that communicates with
application-specific MES
systems. The ability to
test processes under
real conditions at the
SHL location in Böttingen
represents a significant
advantage for the user.
„This makes integration in
later manufacturing at the
user facility simple and
enables a rapid production
start,“ states Daniel
Welte.